Fire-resistant organic products and method for production

ABSTRACT

METHYLOL PHOSPHINES, METHYLOL PHOSPHINES IN COMBINATION WITH AMINE OR AMIDO COMPOUNDS OR WATER SOLUBLE ADDUCTS OF THESE METHYLOL PHOSPHINES AND AMIDES OR AMINES WHEN MIXED AND REACTED WITH MONO, DI OR POLYISOCYANATES WHEREIN THE ISOCYANATE GROUPS ARE ATTACHED TO CARBON ATOMS ARE PARTICULARLY VALUABLE FOR THE PREPARATION OF THERMOSETTING FLAME RESISTANT POLYMERS. THE POLYMERS WHICH ARE PRODUCED ARE CROSSLINKED PHOSPHORUS AND NITROGEN CONTAINING POLYMERS IN WHICH THE REOCCURRING STRUCTURE UNITS EACH CONTAIN A PHOSPHORUS ATOM, THAT IS A COMPONENT OF A RADICAL OF THE GROUP TRIS(METHYLENE)PHOSPHINE (-CH2)3P AND IS LINKED TO AT LEAST ONE ISOCYANATE RADICAL BY CONNECTING URETHANE STRUCTURE. THE POLYMER FORMING SOLUTIONS ARE ALSO VALUABLE FOR THE PREPARATION OF FLAME-, GLOW-, WRINKLE- AND SHRINK-RESISTANT TEXTILES BY IMPREGNATING FABRICS WITH THESE SOLUTIONS AND CAUSING REACTION AND POLYMER FORMATION BY APPLICATION OF HEAT.

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ABSTRACT OF THE DISCLOSURE Methylol phosphines, methylol phosphines in combination with amine or amido compounds or water soluble adducts of these methylol phosphines and amides or amines when mixed and reacted with mono, di or polyisocyanates wherein the isocyanate groups are attached to carbon atoms are particularly valuable for the preparation of thermosetting flame resistant polyr ners. The polymers which are producTd are crosslinked phosphorus and nitrogen containing polymers in which the reoccurring structure units each contain a phosphorus atom, that is a component of a radical of the group tris(methylene)- phosphine (CH P and is linked to at least one isocyanate radical by connecting urethane structure. The polymer forming solutions are also valuable for the preparation of flame-, glow-, wrinkleand shrink-resistant textiles by impregnating fabrics with these solutions and causing reaction and polymer formation by application of heat.

A non-exclusive, irrevocable, royalty-free license in the invention herein described, throughout the World for all purposes of the United States Government, with the power to grant sublicenses for such purposes, is hereby granted to the Government of the United States of America.

This invention relates to new phosphorus and nitrogen containing polymers, processes for their production, and processes of employing these polymers in the fiameproofing of certain organic fibrous material on mixture of various fibers.

In general, this invention relates to polymers capable of being produced by the reaction of a methylol phosphine compound of the formula CHzOH HOCHzl where P is trivalent, R is a HOCH H-, alkyl, aryl or alicyclic group with a monomeric nitrogen compound Which contains one, two, or three isocyanate or isothiocyanate radicals; and to processes of reducing the combustibility of fibrous organic materials. The preferable methylol phosphine for use in this invention is where R is a -CH OH group, When R is a CH OH group the compound is a white crystalline solid M.P. 58 C. and is soluble in Water alcohol and other solvents. For purposes 3,697,316 ad Oct. 10, 1972 of the reaction, each isocyanate group can be considered difunctional as shown in the equation below.

where R can be alkyl, aryl or alicyclic.

We have discovered that tris(hydroxymethyl)phosphine in the presence or absence of HCHO reacts with monomeric aliphatic, aromatic, and cyclic compounds containing at least one member of the group isocyanate radicals, attached to carbon atoms, to produce polymers. The polymers which are produced are crosslinked phosphorus and nitrogen containing polymers in which the reoccurring structure units each contain a phosphorus atom, that is a component of a radical of the group tris(methylene) phosphine [(CH P] and is linked to at least one isocyanate radical by the connecting urethane structure.

We have also discovered that compounds which contain at least one isocyanate radical attached to a carbon atom react with adducts of methylol phosphine (e.g. compounds that contain at least two HOCH groups attached to a trivalent phosphorus atom) and compounds such as melamine, methylol-melamines, cyanamide, urea, thiourea and the like, and by heating form thermosetting polymers which are flame-, rotand mildew-resistant.

The soluble methylol phosphine adducts are prepared by reacting tris(hydroxymethyl)phosphine either in the presence or absence of free formaldehyde with an essen: tially monomeric amide or amine in a suitable solvent. In order to make the soluble and useful adducts of this invention there must be an excess of methylol phosphorus radicals (PCH OH) in the adduct. For purposes of the reaction tris(hydroxymethyl)phosphine is trifunctional, the functionality of the amine or amide is determined by the number of hydrogen or methylol radicals attached to trivalent nitrogen in the compound to be reacted with tris(hydroxymethyl)phosphine. Thus the adduct contains unreacted methylol phosphorus radicals. The adducts are essentially materials which contain the structure of the group consisting of:

where m and n are integers of 1 or 2 and the sum of m+n is 3. Polymers provided by this invention can be produced under acidic, neutral, and alkaline conditions.

Such polymers can be produced in the form of liquid or solid synthetic resins. Such resins can be deposited on the surfaces and/or in the interstices of hydrophilic fibrous organic materials, i.e., organic materials which absorb or adsorb water on most of their surface area. When such organic fiber materials are treated with such resins, they reduce the combustibility of the hydrophilic fibrous organic material and resist removal by laundering, drycleaning, and like chemical treatments. Suchresins sewers can be deposited on the surface of nonhydrophilic ma terials to form flame-resistant coatings. In the case of mixed hydrophilic and hydrophobic fibers the resin can be deposited in and on the surface of the fibers. Such reactions provide valuable new processes and products. Suitable isocyanates which can be used in this invention have the typical structures RNCO or OCNR-NCO where R=H, alkyl or aryl or substituted alkyl or aryl groups. In the case of the aliphatic isocyanates such as hexamethylene diisocyanate, the reaction produces valuable new urethane polymers exhibiting to a rather widely variable controlled degree the properties of a thermosetting noncombustible polymer. Such polymers contain the phosphorus and nitrogen groups of the type described above.

In the case of monomeric aliphatic compounds containing at least one or two isocyanate radicals such as cyclohexadiisocyanate, the reaction produces valuable new flame-resistant polymers containing aliphatic rings and the above described phosphorus and nitrogen groups.

In the case of a monomeric-aromatic compounds containing one or more members of the group which contain at least one or more isocyanate radicals such as toluene diisocyanate, the reaction produces valuable new flameresistant polymers containing aromatic rings and the above described type of phosphorus and nitrogen groups.

Most of the above class of polymers exhibit the unique property of forming intumescent chars when exposed to flame.

The polymers provided by this invention can be formed by reacting the phosphorus compound or adducts with a mixture of the isocyanate compounds.

Hydrophilic fibrous organic materials are rendered flame resistant by impregnating the material with dimethylformamide (DMF) solutions, or homogeneous dispersions of the respective monomers and curing the impregnated materials. Hexamethylenediisocyanate (HMDI) and toluene diisocyanate (TDI) are preferred members of the isocyanate compounds; and tris (hydroxymethyl)phosphine or its amine or amido adducts are preferred members of the phosphorus compounds.

The polymers provided by this invention can be produced in the form of hard brittle polymers, soft rubbery polymers, or semihard polymers. These products can be molded by the conventional techniques of molding thermosetting resins. These polymers are valuable materials for use in the production of molded synthetic plastic articles, such as buttons, food containers, electrical insulators, and the like; synthetic coatings, such as protective coatings and paints, varnishes and the like, having a reduced flammability due to the presence of some of the polymers, paper treating resins, textile resins, and the like.

Condensation polymers of tris(hydroxymethyl)phosphine or the amine or amido adduct with the isocyanate or isothiocyanates are preferably prepared by agitating a mixture of the phosphorus compounds and the isocya nate compound in DMF while heating until polymerizatron occurs. The preferred relative amounts of phosphorus and nitrogen compounds used to polymerize can be calculated by conventional methods used for condensation polymerization by assuming that (1) tris(hydroxymethyl)phosphine is trifunctional, (2) one methylol group of the phosphorus compound condenses with one of the isocyanates or isothiocyanate radicals attached to a carbon atom of the isocyanate compound.

Each isocyanate group can be considered difunctional. For example, one and a half moles of the isocyanate can react With one mole of the tris(hydroxymethyl)phosphine. The preferred ratio of three tenths to three moles of the diisocyanate compound per mole of tris(hydroxymethyl)phosphine.

Tris(hydroxymethyl)phosphine and the amine or amido adducts will copolymerize with materials and are in themselves capable of polymerizing (e.g., diisocya nates) over an extreme wide range. For example, trace quantities of tris(hydroxymethyl)phosphine added to essentially solution of HMDI will copolymerize with HMDI to produce a new phosphorus and nitrogen containing resin. The new nitrogen and phosphorus polymers are formed until the quantity of tris(hydroxymethyl)phosphine or the isocyanate are used up in the formation of the polymer.

Polymerization reactions conducted in accordance with the process of this invention can be carried to the extent of producing solid, liquid, or gel-like polymers. Partial polymers can be isolated, completing the polymerization or partially polymerized thermosetting monomers.

The mixed flame retardant provided by this invention can be used in the treament of organic fibrous textile ma terials such as cotton, flax, linen, rayon, ramie, nylon and the like, as well as blends. Chemically modified fibers such as cyanoethylated, carboxymethylated and aminoethylated cottons and the like; regenerated cellu= losic textiles such as the viscose rayons; or proteinaceous textiles as silk, wool, and the like. The textile materials can be treated in the form of slivers, yarns or fabrics.

' Polymers contained in the mixed flame retardants can be possibility.

Where a textile is being impregnated, it is of advantage to remove the excess impregnating liquid by passing the textileTthrough squeeze rolls adjusted to apply a compara tively extremely high pressure prior to drying and curing the impregnated textile. It is also of advantage to dry the textile at a tempehature of about from 85 C. to about 180 C. for about from 1 minute to about 6 minutes.

Although catalyst are not necessary to make this invention work any of the catalyst systems used in the preparation of durable press fabrics such as Mgcl Zn(NO or the amine hydrochlorides and the like could be used.

The degree of flameproofing imparted to a textile by these phosphorus and nitrogen resins can be varied from a low degree to a very high degree by varying the amount of polymer put in the fabric.

Some advantages of flameproofing textiles in accordance with this invention are as follows: Textiles treated by this process are flame resistant, glow resistant, rotand mildew resistant; the effects of the treatment are permanent, and resistant to laundering, drycleaning, alkali and acid treatments. The polymers themselves are intumescent when we posed to the flame.

The following examples are illustrations of the invention:

EXAMPLE 1 Various organic fibrous materials were impregnated with solutions containing THP and aliphatic and aromatic diisocyanate and isocyanate compounds, dried for 1-3 minutes at 85 C. to C., and cured for 310 minutes at C. to C. All of the treated fabrics with the exception of the nylon, formed a black carbonaceous char when exposed to flame, indicating the presence of phosphorus. The type of material treated, solution composition, dry and cure conditions, and properties of the treated materials are contained in the following table.

Drying conditions Cure conditions Matclh ang e Type of organic fibrous material Soln. Temp. Time Temp. Time test treated used 0.) (111111.) 0.) (min) (deg.) Hand Strength Color Cotton twill fabric A 85 3 155 3 Crisp Fair White Polyester/cotton blend fabric A 85 3 120 10 Do.

001 fabric A 85 3 120 10 No change.

A 85 3 120 10 White. A 85 3 155 4 N change. B 85 3 155 3 White. B 85 3 155 3 do. B 85 3 155 3 No change. B 85 3 155 3 hite. B 85 3 155 3 No change. B 85 3 155 3 White. Cotton twill fabric C 105 1 155 3 Do. Polyester/cotton blend fabric 0 105 1 155 3 Do. W ol C 105 1 155 3 No change.

C 105 1 155 3 White.

0 105 1 155 3 No change. D 105 1 155 4 White. D 105 1 155 4 No change. D 105 1 155 4 hite. 1 D 105 1 155 4 Do. Polyester/cotton blend fabric. D 105 1 155 4 Cotton twill fabric E 85 2 155 3 DO- Polyester/cotton blend fabric E 85 2 155 3 1 Description of solutions used:

A=15 parts THP, 15 parts toluene diisocyante, 70 parts dimethylformamide (DMF). B=7.5 parts THP, 7.5 parts toluene diisocyante, 85 parts drmethylfonnamide.

C=15 parts THP, 15 parts phenyl isocyanate, 70 parts dnnethylformamide.

D=7.5 parts THP, 7.5 parts phenyl isocyanate, 85 parts dimethylformamide.

E=15 parts THP, 15 parts hexamethylene diisocyanate, 70 parts dimethylformamide.

2 Nylon sample resisted burning and melted With the formation of black carbonaceous char containing phosphorus.

EXAMPLE 2 Type of organic fibrous Soln., Match angle material treated used 1 test (deg.) Strength Cotton twill fabric A 160 Good. Polyester/cotton blend fabric. A 160 130. Cotton twill fabric B 160 Fair. Polyester/cotton blend fabric- B 90 Good. Cotton twill fabric C 135 Do. Polyester/cotton blend fabric O 135 Do.

1 Description of solutions used:

A=THP-cyanamide adduct [62 parts THP, 21 parts cyanam1de (50%), 18 parts fonnalin, 90 parts H2O, heated for 10 nnn.]; 40 parts of adduct 1r nixed with parts hexamethylene diisocyanate, and 15 arts DM B THP-cyanamide adduct [62 parts THP, 21 parts cyanamide (50%), 18 parts formalin, 90 parts H20, heated for mm]; 40 parts of adduct mixed with 5 parts toluene diisocyanate and parts DMF C =THPcyanamide adduct [62 parts THP, 21 parts cyanamido (50%), 18 parts formalin, 00 parts H2O, heated for 10 mm]; parts of adduct mixed with 5 parts phenyl isocyanate and 15 parts DMF.

EXAMPLE 3 A solution containing 15 parts THP, 15 parts toluene diisocyanate, and 70 parts DMF was steam heated to evaporate the solvent, then heated in an oven at 155 C. for 30 minutes which resulted in the formation of clear, pale yellow, hard polymer which resisted burning when exposed to flame and formed a black char. Polymer" was insoluble in water and ethanol.

EXAMPLE 4 A solution containing 15 parts THP, 15 parts phenyl isocyanate, and 70 parts DMF was steam heated to evaporate the solvent, then heated in oven at 155 C. for 30 minutes which resulted in the formation of clear, pale yellow, hard polymer which resisted burning when exposed to flame and formed a black char. Polymer was insoluble in water and ethanol.

EXAMPLE 5 A THP-cyanamide adduct was produced by heating for 10 minutes a solution containing 62 parts THP, 21 parts of 50% cyanamide, 18 parts formalin, and parts H O. Forty parts of this adduct was mixed with 5 parts of hexamethylenediisocyanate, and 15 parts of DMF. The solvent was evaporated from the solution by heating with steam, then the mixture was heated in an oven at C. for 30 min. to form a clear, pale yellow, hard polymer which resisted burning when exposed to flame, and formed a black char. Polymer was insoluble in water and ethanol.

EXAMPLE 6 Forty parts of the THP-cyanamide adduct which was prepared as shown in Examle 5, was mixed with 5 parts of toluene diisocyanate and 15 parts DMF. The solution was steam heated to evaporate the solvent then heated in an oven at 155 C. for 30 minutes to form a yellow, brittle, porous polymer which resisted burning when exposed to flame and formed a black char. Polymer was insoluble in water and ethanol.

EXAMPLE 7 Forty parts of the THP-cyanamide adduct which was prepared as shown in Example 5, was mixed with 5 parts of phenyl isocyanate, and 15 parts DMF. The solution was steam heated to evaporate the solvent then heated in an oven at 155 C. for 30 minutes to form a clear, pale yellow, hard polymer which resisted burning when exposed to flame and formed a black char. Polymer was insoluble in water and ethanol.

We claim:

1. A process for reducing the flammability of a textile by means of a resin coating which comprises impregnating said textile with the inert solvent solution of a phos phorus containing reagent consisting of tris (hydroxymeth yl)phosphine in combination with an inert solvent solution of a monomeric isocyanate reagent containing a plurality of isocyanate groups, the phosphorus containing material and the isocyanate material being present in the mole ratio of about from 1:3 to about 3:1, drying the impregnated textile, and curing for a suitable length of time.

2. The process of claim 1 wherein the textile is cotton.

3. The process of claim 1 wherein the textile is W00].

4. The process in claim 1 wherein the textile is paper.

5. The process in claim 1 wherein the textile is leather.

6, .[he process in claim 1 wherein. the textile is a poly ester cotton blend,

7. A process for reducing the flammability of a textile by means of a resin coating which comprises impregnating said textile with the inert solvent solution of a soluble methylol phosphine adduct prepared by reacting tris(hydroxymethyDphosphine with an essentially monomeric amide or amine Which contain structures of the group consisting of (HOCHQ P(CH N) Where m and n are integers of one or two and the sum of m-i-n is 3, in cornbination with an inert. solvent solution of a monomeric iso cyanate reagent containing a plurality of isocyanategroups, drying the impregnated textile, and curing for a suitable length of time. 7 4

8. The process in claim 7 wherein the textile is cotton.

9. The process in claim '7 wherein the textile is Wool.

10. The process in claim 7 wherein the textile is paper.

11. 'The process in claim 7 wherein the textile is leather,

12. The process in claiim 7 wherein the textile is a blend of polyester-cotton. ,1 References Cited 1 7 UNITED STATES PATENTS 2,937,207 5/1960 Reuter et al. 117-136 X 3,030,421 4/1962 Renter et a1. 260-6065 P 3,213,042 10/1965 Buckler et al 117---136 X 3,268,360 8/1966 Beninate et al. 117-136 WILLIAM D. MARTIN, Primary Examiner T. G. DAVIS, Assistant Examiner Us. 01. X.R. V Ill-138.8 F, 138.8 N, 141, 142, 143 A, 155 R; 

